Method of packaging flat articles



Sept. 16, 1969 R. H. PRATT METHOD OF PACKAGING FLAT ARTICLES ssheets-sheet 1 Filed May 5. 1966 INVENTOR ROBERT H. PRATT BY @newATTORNEYS Sept. 16, 1969 R. H. PRATT METHOD OF PACKAGING FLAT ARTICLES 5Sheets-Sheet Filed May 5. 1966 INVENTOR H. PRATT 4 ROBERT ATTORNEYSSept. 16, 1969 R. H. PRATT 3,466,836

METHOD OF PACKAGING FLAT ARTICLES Filed May 3, 1966 5 Sheets-Sheet 5INVENTOR ROBERT H. PRATT ATTORNEYS United States Patent O 3,466,836METHOD F PACKAGING FLAT ARTICLES Robert H. Pratt, Milwaukee, Wis.,assignor to Pratt Manufacturing Corp., Milwaukee, Wis., a corporation ofWisconsin Filed May 3, 1966, Ser. No. 547,324 Int. Cl. B65b 9/08, 9/12,51 /30 U.S. Cl. 53-28 10 Claims ABSTRACT 0F THE DISCLOSURE A method ofpackaging comprising continuously advancing web portions which are toform the opposite panels of a package, assembling adjacent parts of theadvancing web portions to provide a relatively short upstanding invertedV between said panel portions, continuously sealing upper portions onlyof said inverted V to each other along a longitudinal path, thereaftercontinuously folding the advancing panel portions upwardly to provide aW formation, dropping merchandise in longitudinally spaced relationshiponto said panel portions on each side of the inverted V, continuouslysealing the upper longitudinal edges of the web portions, transverselyconnecting the web portions between items, and transversely cutting thepackages.

This invention relates to improvements in method of packaging flatarticles such as surgical Sponges, which method is applicable to thepackaging of any materials requiring a separation.

In my Patent No. 2,997,166 there is disclosed a package having its upperedge folded in the form of an inverted W, which package is very usefulin the packaging of ilat articles such as surgical supplies because eachof the infolded portions of the package protects a portion of a sterilearticle such as a surgical sponge, which sponge portion is overlapped bysaid infolded package flap both during and after opening of the package.In addition the construction of my prior patent makes it possible for anurse or other attendant to grip both of the Sponges while the latterare protected between the infolded ap portion and coacting panel, eachsponge being available for easy withdrawal by the surgeon for useindependently of the other.

Patent No. 3,192,685 discloses a machine for continuously manufacturingand loading packages of the type shown in my Patent No. 2,997,166. Inproducing this type of package it has been found very desirable toutilize a pressure-sensitive adhesive such as latex for certain of theseals, which adhesive is pre-applied to the web. Such latex typeadhesive is desirable for sealing the side edges of the package, and itis highly desirable to utilize a heat seal or glue to secure theinfolded aps to each other.

When manufacturing the style of package shown in FIGS. 9 or 10 of myPatent No. 2,997,166, wherein there are the extra outfolded flaps at 125and 225, the apparatus of Patent No. 3,192,685 is very practical andefficient because the latex strips can all be applied to the same sideof the web in the pattern shown in FIG. 13 of said Patent No. 3,192,685.To try to manufacture a package of the type shown in FIG. 7 of my PatentNo. 2,997,166 on apparatus such as shown in Patent No. 3,192,685, wherethe side edges are to be sealed by latex, has presented problemsbecause, if the side edges of the package are to be thus connected, thiswould require the latex for sealing said side edges to be applied on oneside of the web and the latex for securing the infolded flaps togetherto be applied to the other side of the web. Where latex strips areapplied to two sides of a web they lCC will stick to each other in theroll wherever there is an overlap. In addition, any latex on an outerside of the blank is likely to be removed or loosened to an extent whichmay affect the seal. To try to heat seal the joint 19 of FIG. 7 of mypackage Patent No. 2,997,166 is not possible with either the method ofproduction of said patent or with the method disclosed in apparatusPatent No. 3,192,685 as there is no access for such heat seal and it isdiicult to apply liquid glue.

It is a general object of the present invention to provide a method offorming W-fold packages and of packaging merchandise therein which ismore simple than the method of Patent No. 3,192,685, and which makes itpractical to use a heat seal on one side such as for securing theinfolded flaps to each other (see the connection 19 of FIG. 7 of PatentNo. 2,997,166) whereby latex strips may be successfully used on theother side of the web for making the other seals.

A further object of the invention is to provide a method of formingW-fold packages and packaging merchandise therein in which infoldedprotecting flaps are formed at the bottom of the package as the web isbeing continuously advanced, so that the flat Sponges or other productcan be expeditiously dropped into proper position between the aps andpanels by automatic machineryV or by hand, with gravity aiding in thefeed process. With the method of Patent No. 3,192,685, the package isformed in a reverse position, with the infolded aps on top so that theproduct must be laid in position at an earlier stage and the flaps thenfolded down over the product. This sometimes produces problems, and doesnot insure an accurate insertion of the product in proper flap-protectedposition.

With the above and other objects in view, the invention consists of theimproved method of packaging and all of its steps, as set forth in theclaims, and all equivalents thereof.

In the accompanying drawings illustrating several embodiments of themethod:

FIG. 1 is a diagrammatic view, generally in side elevation, showing theimproved method;

FIG. 2 is a top view of the apparatus illustrated in FIG. 1;

FIG. 3 is a sectional view taken on line 3 3 of FIG. 1;

FIG. 4 is a sectional view taken on line 4 4 of FIG. 1;

FIG. 5 is a sectional View taken on line 5 5 FIG. 1;

FIG. 6 is a sectional view taken on line 6 6 FIG. 1;

FIG. 7 is an edge view of the finished package;

FIG. 8 is a plan view of the finished product;

FIG. 9 is a fragmentary side elevational view like the left hand portionof FIG. 1 showing a modification wherein the process of FIG. 1 may becarried out with two separate rolls instead of from a single roll ofstock;

FIG. 10 is a plan view of the apparatus illustrated in FIG. 9;

FIG. 1 is a fragmentary side elevational view like FIG. 10 showing howthe process may be carried out with a single roll of stock which,however, is slit after it comes off of the supply roll and before itreaches the former;

FIG. 12 is a plan view of the apparatus shown in FIG. 11;

FIG. 13 is a side elevational view of another modiiication showing howthe process may be carried out using two vertically-disposed supplyrolls; and

FIG. 14 is a top plan view of the apparatus shown in FIG. 13.

Referring more particularly iirst to FIGS. 1 and 2, the package hereillustrated is preferably formed of a thin,

non-transparent packaging paper such as white sulphite. While othermaterials may be used, such as glassine, polyethylene, or the like, theimproved method has its greatest utility when using the first-mentionedtype of paper. While the package to be formed is suitable for varioustypes of merchandise, it is particularly useful in connection with gauzepads, surgical dressings, surgical Sponges, rubber gloves, and the like.

In carrying out the improved method of FIG. 1 a supply roll of thematerial is suitably supported on a horizontal axis for unrolling. Therst step of the process is to form the web with an upstanding, centralinverted V-fold portion 21. This may be accomplished in several ways butit is prefered to use a forming plate 22 having a V-shaped receiving end23 over which the paper is drawn to start the fold line 24 which is toform the apex of the fold. The upfolded material is then suitably sealedtogether. The present method makes it practical to use a heat seal. Thismay be accomplished by having7 a web precoated on its underside with aheat-scalable material 25 (FIG. 3). Where the web is a non-transparentpackaging paper such as white sulphite this heat seal coating wouldnormally be a polyethylene coating material or other material which isresponsive to heat to bring about a seal.

As an alternative, glue or other liquid or settable adhesive may beapplied within the fold 21 before it is finally squeezed together. Thismay be accomplished by having a glue gun 26 extending into the fold todischarge glue therein as shown in FIG. 1. Where there is the heat sealcoating 25, the heat sealing step may be accomplished in any desiredmanner such as by pressure and heat-sealing wheels 27 which engage theupstanding V-fold portion 21, as shown in FIGS. 1 and 2. Where glue isapplied instead of a heat seal coating, the wheels 27 may serve only aspressure rolls.

As the next step in the method it is desirable with most materials totrim off the folded edge as at 24', FIG. 1, leaving the cut-off portionssealed together therebelow as in FIG. 5. With some materials suchtrimming is not essential as the flaps can be readily separated alongthe fold line 24. The trimming can be accomplished by slitter wheels 29or in any other suitable manner. The two sides of the web are then helddown on opposite sides of the upstanding fold portion 21 by former rolls30, which are angled as illustrated in FIG. 2 to engage on oppositesides of the upstanding fold portion 21.

The sides of the web, after the web emerges from the former plate as inFIG. 5, which sides are to form opposite panels of the package, are thenfolded up to complete the W as shown in FIG. 6, and while the panels arein approximately the position of FIG. 6, in the case of surgical Spongesor other at articles they may be dropped in position as shown at 31(FIG. 6), with the lower edges lof the articles naturally gravitating toa position within the fold between its side panel portion and theadjacent upfolded flap 32.

In the preferred embodiment of the method, where a non-transparent papersuch as white sulphite is employed, it is preferred that the oppositeside edges of the upper side of the web emerging from the supply rollhave pre-applied, longitudinal strips of latex or otherpressure-sensitive adhesive in the locations indicated at 33 in FIG. 1,and that there be longitudinally-spaced transverse strips ofpressure-sensitive adhesive at locations such as indicated at 34 in FIG.8. Where pre-applied latex is not present on the supply roll, glue orthe like may be applied to the strip portions 33 on the top side of theweb at a suitable stage in the process or a heat seal may be employed.In either case the transverse seals 34 may be sealed by heat sealing(when latex is not used) and in this case must have a heat seal coating.

In any event, in carrying out the method, the juxtaposed upper edges ofthe package are subjected to sealing pressure, preferably betweenpressure wheels 35. If this 4 upper edge seal is to be a heat seal, thenthe wheels 35 must be heated to perform a heat sealing operation.

A desirable, but not essential, additional step in the method is to trimthe sealed upper edge as at 36. This may be accomplished in any suitablemanner, such as by use of slitter wheels 37. If the cross seals arelatex as at 34 these are pressed together between rotatably supportedpressure bars 38 suitably driven by wheels 39. If, on the other hand,the cross seals are to be accomplished by heat sealing, the pre-appliedheat seal coating is subjected to both heat and pressure by the bars 38,the latter having suitable heating elements therein. Thereafter thecompleted packages are cut off as at 40, which may be accomplished byknives 41 driven by wheels, the finished package 43 dropping off asshown at the right in FIG. 1.

It is thus apparent that with this improved method the cross seals andtop edge seals may be eiected by the pressure sealing of latex strips orby heat sealing, and the sealing of the infolded flaps 32 may beaccomplished either with glue or with a heat seal as desired, or latexmay be used if it is not being applied to the reverse side of the web.It is preferred, however, to use the heat seal or glue at 25, as in FIG.l, to permit use of latex strips on the opposite side of the web. It isalso apparent that because of the improved method the insertion of theproducts by gravity, as indicated in FIG. 6, may be accomplished veryeasily either by hand or by automatic insertion machinery with assurancethat the articles will be properly inserted between the folds of thepackage.

In the form of the invention illustrated in FIGS. 9 and 10 the method ofprocedure is the same except that there are two separate supply rollswhich are placed end-to-end and which feed separate web portionsalongside one another. While these two supply rolls may carry the samekind of material, the method makes it practical to use two differentmaterials in forming the package. For example, one of the supply rollsmay be polyethylene film or glassine, and the other supply roll may benontransparent paper such as white sulphite. Also, regardless of whetherthe same types of stock are used on the two supply rolls, only one needbe printed. The two webs are suitably guided through and beneath rollers128 to a former, which former is the same as has been illustrated anddescribed in connection with FIGS. 1 and 2. Here the procedure is thesame as heretofore described in connection with FIGS. 1 and 2 exceptthat the slitting wheels 129 merely do a trimming job as the upper edgesof the upfolded aps are already separate from each other. From thispoint on, the method is the same as heretofore described in connectionwith FIG. 1.

In the form of the invention of FIGS. 11 and 12 the method is also thesame except that here the method starts with a single supply roll 220 asin FIG. 1, but the roll is slit into two webs prior to forming, whichslitting may be performed by a slitting wheel 280. From this point on,the method is the same as has heretofore been described in connectionwith the form of the invention of FIG. 9.

In the form of the invention of FIGS. 13 and 14 there are two separatedsupply rolls 320, mounted on vertical axes, from which the webs are fedto merging relationship between vertical rolls 390, Just as in the formof the invention of FIGS. 9 and l0, here one supply roll may carry onekind of material and the other one a different type. Also, one may beprinted and the other plain. Thereafter the upper edge of the twovertically-disposed strips may be glued together by the action ofpressure rolls 327, glue having been previously applied in advance ofthe rolls 390 or, if the inner faces of the merging webs have beenprecoated with a heat seal coating material, then they may be heatsealed together by the use of heat and pressure from the sealing wheels327. Thereafter, the connected meeting edges may be trimmed as at 340 byslitters 341 and the sides of the web are then folded upwardly betweenthe rollers 391 to produce the W-fold formation with the upstandingfolded portion 321. From this point on, the method can be the same as inthe form of the invention of FIG. 1.

It is apparent from the above that with all of the methods heretoforedescribed the same result shown in FIG. 6 is produced, whereby the padscan be inserted manually or automatically into position with the aid ofgravity, and wherein the packages may be then closed and sealed toproduce the final package Of FIG. 8.

The package of FIG. 8 is adapted to be used in the same manner as thepackage shown in my Patent No. 2,997,166, i.e. the thumbs are insertedwithin the bottom of the inverted V and the two halves of the packageare pulled apart to break the seal 25, whether it be a heat seal, latexor glue. If the upper edge of the inverted V has been trimmed off as at24, or if the upper edges of the protecting iiap portions 32 are alreadyseparate as in the form of the invention of FIGS. 9 and 10 and 13 and14, continued pulling apart will readily open the side seals 34. Thusthe party opening the package can hold one surgical pad between one iiapand the adjacent panel, and the other surgical pad between the otherflap and the adjacent panel. The aps completely protect the surgicalpads from contamination. Thereafter the surgical pads may be eithershaken out or removed by a forceps one at a time as required. While itis preferred, in the final package, that the material at the apex of theinverted V be unconnected, such as results from the trimming off of thepiece 24', nevertheless with certain materials the package is fullyusable even if no trimming is done, it being merely necessary whenbreaking the seal 32 to also tear apart the flaps at their apex 24,certain materials being sufficiently weakened by the fold line 24 tofacilitate such tearing.

All forms of the method present the following options:

(1) A heat seal pattern on one side of the web with a glue pattern onthe opposite side.

(2) A pressure-sensitive latex pattern on one side of the web with glueon the opposite side.

(3) A heat seal pattern on both sides.

(4) A heat seal pattern on one side of the web and a pressure-sensitivelatex pattern on the opposite side.

In the claims the term sealing or sealingly connecting is intended tocover any type of connection, such as heat seal, pressure-sensitivelatex, or glue.

In addition to the above the use of two separate rolls, as in the formof the invention of FIGS. 9 and 10 and 13 and 14, makes it practicalwith these methods to use two kinds of material in forming the package.For example, one roll may be polyethylene film and the other roll may bepaper such as white sulphite. This is an advantage in certain packageswhere transparency on one side may be desirable. The use of two separaterolls in these modifications also makes it possible to economicallyapply all printed matter to one of the webs only, it being unnecessaryto have any printing -on the web forming the back panel of the package.In the claims the expression web portions contemplates either connectedweb portions as in FIG. 1 or separate web portions asin FIGS. 9 and l00r 13 and 14.

In the form of the invention of FIGS. 9 and 10 all parts whichcorrespond to similar parts in FIG. 1 are designated by the samenumerals preceded by the digit 1; in the form of the invention of FIGS.1l and 12 all parts which correspond to similar parts in FIG. l aredesignated by the same numerals preceded by the digit 2; and in the formof the invention of FIGS. l3 and 14 all parts which correspond tosimilar parts in FIG. 1 are designated by the same numerals preceded bythe digit 3.

While in the illustrated embodiment the invention has been described andillustrated to show its applicability to the packaging of surgicalSponges, it is obvious that the method is applicable to the formation ofW-fold packages for a variety of uses wherein the upfolded ap portions32 may act as separators in the package and, depending upon themerchandise being packaged, the flaps 32 may vary in the amount whichthey project upwardly within the package.

Various other changes, adaptations, and modifications may be madewithout departing from the spirit of the inl vention, and all of suchchanges are contemplated as may come within the scope of the claims.

What I claim is:

1. A method of packaging comprising continuously advancing web portionswhich are to form the opposite panels of the package, continuouslyfolding adjacent parts of said advancing web portions a short distanceupwardly to provide an upstanding inverted V between said panel portionswhich is of substantially less height than the corresponding dimensionsof said panel portions so that the opposite side of the inverted Vprovide separating flaps in the package being formed, with lower foldlines between said aps and panel portions, continuously sealing upperportions only of said separating iiaps to each other along alongitudinal path before folding said panel portions upwardly,thereafter continuously folding the advancing panel portions of the webupwardly to provide a W formation in conjunction with said inverted V,dropping merchandise which is of greater height than said inverted V inlongitudinally-spaced relationship onto said panel portions withmerchandise received in each lower edge fold and separated by saidseparating flaps, continuously sealingly connecting the upperlongitudinal edges of the panel portions, transversely sealinglyconnecting the web along longitudinally-spaced paths located betweenmerchandise, and transversely cutting olf packages intermediate thewidth of said transverse seal paths.

2. A method of packaging as set forth in claim 1 in which the webportions are initially advanced in integral form.

3. A method of packaging as set forth in claim 1 in which the webportions are initially advanced in integral form and which includes thestep of continuously trimming ofi the top of the inverted V after thelatter has been folded upwardly and before the panel portions have beenfolded upwardly.

4. A method of packaging as set forth in claim 1 which includes the stepof trimming olf the top of the inverted V after the latter has beenfolded upwardly and before the panel portions have been folded upwardly.

y5. A method of packaging comprising continuously advancing web portionswhich are to form the opposite panels of the package in separatecondition alongside one another in the same plane, continuously foldingadjacent parts of said advancing web portions to provide an upstandinginverted V between said panel portions so that the opposite sides of theinverted V may provide separating flaps in the package being formed7with lower fold lines between said aps and panel portions, continuouslysealing upper portions only of said separating flaps to each other alonga longitudinal path, continuously folding the advancing panel portionsof the web upwardly to provide a W formation in conjunction with saidinverted V, dropping merchandise in longitudinally-spaced relationshiponto said panel portions with merchandise received in each lower edgefold and separated by said protecting flaps, continuously sealinglyconnecting the upper longitudinal edges of the panel portions,transversely sealingly connecting the web along longitudinally-spacedpaths located between merchandise, and transversely cutting off packagesintermediate the Width of said transverse seal paths.

6. A method of packaging comprising initially advancing web portionswhich are to form the opposite panels of the package in separatecondition alongside one another in vertical planes, continuously sealingupper portions only of said web portions to each other along alongitudinal path to provide separating flaps, thereafter continuouslyfolding the advancing panel portions of the web upwardly on fold linesspaced below said sealing path to provide a W formation in conjunctionwith said separating aps, dropping merchandise in longitudinallyspacedrelationship onto said panel portions with the merchandise received ineach of said fold lines and Separated by said separating aps,continuously sealingly connecting the upper longitudinal edges of theweb portions, transversely sealingly connecting the web portions alonglongitudinally-spaced paths located between merchandise, andtransversely cutting off packages intermediate the width of saidtransversely sealed paths.

7. A method of packaging as set forth in claim 1 in which the seals forthe opposite panels are performed by pre-applying a pressure-sensitiveadhesive to one side of the web only and by pre-applying another type ofsealing material to the other side of the web at a location for sealingthe separating aps.

8. A method of packaging as set forth in claim 1 in which the upperportions of the separating flap portions of the inverted V arecontinuously heat sealed together on a line extending longitudinallythereof before said panels are folded upwardly.

9. A method of packaging as set forth in claim 1 in which the upperportions of the separating flap portions of the inverted V arecontinuously longitudinally heat sealed together before the panels arefolded upwardly and in which the upper longitudinal edges and transverseseals of the panel portions are thereafter continuously pressure sealed`10. A method of packaging as set forth in claim 1 in which thecontinuous sealing of the upper portions only 0f the separating aps ofthe inverted V t0 each other along a longitudinal path is performed byapplying glue to said portions longitudinally thereof and within theinverted V after formation of the latter and before the panels arefolded upwardly.

References Cited UNITED STATES PATENTS 2,565,444 `8/1951 Waters 53-28 X3,344,915 10/ 1967 Rawlings 206-56 THERON E. CONDON, Primary Examiner E.F. DESMOND, Assistant Examiner U.S. C1. X.R. 53-180

